Inclusions In Steel Research Articles

Effect of Cerium on the Cleanliness and Properties of an Al‐Killed Low‐Sulfur Steel

Effects of the cerium content on inclusions, microstructure, and performance of an Al‐killed low‐sulfur steel are studied. As the cerium content in the steel increases from 0 to 190 ppm, the evolution path of the inclusion composition is Al2O3→CeAlO3→Ce2O2S + Ce2O3, and the inclusion size first decreases and then increases. When the cerium content is 76 ppm, the inclusion size reaches the minimum value. The addition of the ferrocerium is beneficial to the grain refinement of the Al‐killed low‐sulfur steel due to the low disregistry between inclusions and the steel matrix. The grain size of the steel decreases first, and it changes little after the cerium content reaching 76 ppm. The grain refinement is beneficial to increase steel properties. However, excessive inclusions in steel with a high cerium content reduce the tensile strength and the plasticity of the Al‐killed low‐sulfur steel.

The Analysis of the Effect of Mischmetal Addition on the Formation of Non-Metallic Inclusions in Liquid Steel

The study focuses on the effect of rare earth elements (REM) in mischmetal on the morphology and chemical composition of non-metallic inclusions in pre-oxidised steel. Calculations were carried out using the WYK_STAL computer program according to two calculation models, considering/ignoring the sulphur partition coefficient at the liquid steel-liquid slag interfacial boundary. It was found that the chemical composition of the resulting precipitates is a consequence of the order in which deoxidising additives were admixed. Simulations confirmed the presence of Ce oxides and sulphides. This was also confirmed by the analysis of samples taken from the steel ingot after laboratory melting. Non-metallic inclusions Ce2O3 and CeS, and the complex of precipitates: La2O3-Ce2O3 was also identified in the steel. Introduction of mischmetal in the final stage refining is the most effective method. Therefore, the oxygen content is reduced below 0.001%, and the sulphfur content can be reduced to 0.004%.

Deoxidation of steel with calcium carbide. Influence of calcium carbide addition on steel contamination by non‑metallic inclusions

One of the main factors determining the final properties of metal products is the quantity, morphology and distribution of non‑metallic inclusions in steel. The article deals with the issues related to the use of calcium carbide in steelmaking production, instead of secondary aluminum and other deoxidizing materials, in order to improve the quality of the products. During the experimental work on the use of calcium carbide in steelmaking production, instead of secondary aluminum and other deoxidizing materials, second grade calcium carbide according to GOST 1460–81 was used. To determine the contamination of steel with non‑metallic inclusions, sampling was carried out from hot‑rolled products obtained from continuously cast billets. According to the results, it was found that the improvement of melt deoxidation in melts using calcium carbide can be achieved by increasing its consumption. In turn, the use of calcium carbide for deoxidation of the melt upon its release from the electric arc furnace into the ladle, instead of secondary aluminum ingots of grade AB87 according to GOST 295–98, helps to reduce the contamination of steel with non‑metallic inclusions.

Phase evolution at interface between magnesia refractories and low-density steel/slag by Mg/Ca mass transfer

This study investigated the interfacial phase evolution between magnesia refractory and low-density molten steel with different Al contents (0.5 % and 10 %) during the steel-slag reaction. Simulated experiments involving a refractory-steel-slag coupling reaction were conducted under laboratory conditions. The thickness and compositional distribution of the interface layers formed after the refractories were exposed to molten steel and slag were analyzed. The results indicate that, in the absence of slag, a MgAl2O4 layer is formed at the interface between the refractory and molten steel due to the reaction between [Al] and Al2O3 inclusions in the molten steel with the refractory. Upon the addition of slag, CaO in the slag is reduced to Ca and transferred into the molten steel, modifying the solid MgAl2O4 layer at the interface into a primarily liquid CaO·MgO·Al2O3 layer. The liquid interface intensified the erosion of the refractory by the molten steel, resulting in a thickened interface layer. The higher the Al content in the steel, the greater the degree of modification of the CaO·MgO·Al2O3 layer by Ca. The Mg/Ca mass transfer process during the steel-slag reaction was simulated using the FactSage Macros calculation, and the differences in mass transfer between low and high Al contents were compared. The results indicate that under high Al conditions, the supply of Mg/Ca increases significantly. The simulation results were compared with numerous findings in the literature, confirming the accuracy of the simulation.

Development of a methodology for determining the content of non-metallic inclusions in steel

As part of the study, a method was proposed for assessing the metal purity for non-metallic inclusions using optical emission spectrometry. To assess the content of non-metallic inclusions in the slabs, two columns of metal were selected from two slabs of low-alloy metal deoxidized with aluminum. Each column was divided into seven samples in the direction from the small radius of the continuously cast ingot to the large one. We studied these samples to assess metal contamination with non-metallic inclusions using quantitative optical metallography according to ASTM E1245-03, fractional gas analysis (FGA) and optical emission spectral analysis PDA. Analysis of the samples according to ASTM E1245-03 standard showed that in all samples the percentage of oxides and sulfides is on average 10 and 90 %, respectively. According to the results of FGA, it was concluded that such non-metallic oxide inclusions as aluminates predominate in the metal samples of both ingots. A comparison was made between the results of the determination of oxygen in non-metallic inclusions obtained by FGA method and the number of sparks in inclusions at the analysis by PDA method; analysis of the dependencies showed that there are two clearly defined point distributions. To carry out PDA analysis, a program was deve­loped that allows determining the number of inclusions of various types and calculate their volume fraction.

Effect of Ferrosilicon Deoxidation on the Evolution and Removal of Oxide Inclusions in 55SiCr Spring Steel

Effect of Ferrosilicon Deoxidation on the Evolution and Removal of Oxide Inclusions in 55SiCr Spring Steel

Study on the effect of Al-La composite deoxidation on the modification behaviors of TiN and sulfide inclusions in 20CrMnTi gear steel

This article uses experimental and thermodynamic calculations to study the directional modification behavior of TiN and sulfides in 20CrMnTi steel before and after the addition of rare earth La element. The morphologies (SEM) and elemental distributions (EDS) of TiN and sulfide inclusions in steel are characterized using scanning electron microscopy, and the sizes of the inclusions are statistically analyzed. With the addition of rare earth La, the average sizes of TiN and sulfide inclusions in steel decrease, and the proportions of TiN and sulfide inclusions in all inclusions of the steel decrease. The results show that the addition of La element can promote the formation of LaAlO3 in steel, which can be used as the nucleation core of TiN and MnS inclusions in steel, and then form LaAlO3-TiN and LaAlO3-MnS-TiN composite inclusions, which are smaller in size and more uniform in distribution than TiN and sulfide in steel before La element is added. When La is added alone, the average size of TiN inclusion in steel is 2.2 μm. After the deoxidation of Al-La alloy, the average size of TiN inclusion in the steel is 1.9 μm. After Al-La composite deoxidation, the TiN containing inclusions in the steel will be transformed into smaller LaAlO3-TiN composite inclusions. When adding La alone, the average size of sulfide inclusions in the steel is 2.1 μm. When Al-La composite deoxygenation is used, the average size of sulfide inclusions in steel is 1.1 μm, indicating that the Al-La composite deoxygenation has a better improvement effect on sulfide inclusions in steel than the improvement effect of adding La alone.

Evolution of inclusions in DH36 grade ship plate steel during high heat input welding

In this paper, the solid solution and precipitation behavior of inclusions on the surface and 1/2 thickness of the tested steel plate under the condition of welding heat input of 400 kJ/cm is investigated by using laser confocal experiments with hot-rolled state DH36 ship plate steel as the research object, and the mechanism of the effect of inclusions on the phase transformation of an acicular ferrite is revealed. The results show that the inclusions of the tested steel are mainly composed of Oxide-MnS, MnS, Oxide, TiN, Spinel, etc. The amount of inclusions on the surface of the tested steel plate is significantly higher than that at the 1/2 thickness position. During the heating stage, the small inclusions on the surface immediately disappeared, and the large inclusions gradually solidified in the matrix; atomic diffusion occurred at the bond between the inclusions and the matrix; while the small inclusions at the 1/2 thickness position gradually disappeared at the beginning of the heating stage, and the inclusions began to precipitate and grow when the temperature was increased to 990 °C. The acicular ferrite preferentially nucleates and grows near the boundary of the inclusions during the post-weld cooling stage, and its growth ends when two acicular ferrites cross.

First‐Principles Calculation and In Situ Observation on the Precipitation of Inclusions during Solidification of a High Sulfur Steel

The precipitation process of inclusions in the high sulfur steel with the cerium addition is observed using the high‐temperature confocal scanning laser microscope (CSLM). Rare earth (Re) inclusions formed in the molten steel, and MnS inclusions precipitate along grain boundaries or on oxide cores at the end of solidification. With the addition of cerium, the average aspect ratio of inclusions in the steel decreases from 6.5 to 5.0, and the addition of cerium effectively modifies the elongated MnS. Thermodynamic calculations show the inclusion transformation during solidification, yet it lacked the formation of Ce2O2S and Re sulfides. According to the first‐principles calculation, the priority of the inclusion formation was Ce2O3 > CeAlO3, Ce2O2S > CeS > Ce3S4 > MnS. The stability of MnS inclusions is much lower than that of cerium‐containing inclusions. It is in situ observed that the addition of cerium promotes the formation of cerium‐containing inclusions and reduces the precipitation of MnS in the high sulfur steel.

Process Parameter Optimisation in Laser Powder Bed Fusion of Duplex Stainless Steel 2205

Additive Manufacturing (AM) appears as a very interesting alternative to conventional production routes for alloys and metals, thanks to the fact that at the end of printing, the final product is obtained directly. The present article looks for the inclusion of duplex stainless steel 2205 (DSS-2205) in the commercial catalog of steels utilized in powder bed fusion (PBF) technologies, specifically applying the selective laser melting (SLM) technique. The main objective is to establish optimal printing parameters that reproduce the closest results to the base material properties. To achieve this, the response surface method was used in the methodology and experimental design, studying the parameters of laser power, scanning speed, and hatching distance. A reference material, machined from a hot-rolled plate, was utilized to compare the results obtained through tensile strength. Lastly, the optimal parameters have been obtained for this stainless steel. Additionally, a study of heat treatments has been developed, aiming to optimize the austenitization process, achieving an improvement in mechanical properties. A steel with mechanical properties practically identical to those of steel produced using conventional techniques has been obtained through SLM.

Effect of Interface Property on the Agglomeration Characteristic of Inclusions in High Al Steel with Different Al Contents

Herein, a 3D stability diagram is established in the AlON system. Based on that, four sets of experiments with different Al contents are designed to prepare different inclusions. Subsequently, the agglomeration behavior of inclusion is observed in situ by using confocal laser scanning microscopy (CLSM) combined with an infrared image furnace. The sample with inclusions is heated to melt and the agglomeration behavior of inclusion is recorded by the CRT monitor of CLSM. The calculated agglomeration force of inclusion shows that when the Al content increases from 0.5 to 3 pct, the agglomeration force of Al2O3 inclusions decreases from 7.2 × 10−16 ≈ 6.0 × 10−14 N to 1.2 × 10−16 ≈ 3.2 × 10−15 N. As the Al content increases from 6.5 to 10 pct, the agglomeration force of AlN inclusions increases from 2.2 × 10−17 ≈ 1.1 × 10−15 N to 1.7 × 10−16 ≈ 7.9 × 10−15 N. The theoretical calculation also shows that the agglomeration force of Al2O3 inclusions decreases and that of AlN inclusions increases with the increasing Al content. When the Al content is >4.7 pct, the agglomeration force of AlN inclusions is larger than that of Al2O3 inclusions.

Effect of ladle slag composition on the cleanliness of Al-Ti deoxidized interstitial-free steel

The effect of slag composition on the cleanliness of Al-Ti deoxidized interstitial-free steel produced via basic oxygen furnace (BOF)-ladle furnace (LF)-Ruhrstahl-Heraeus (RH)-continuous casting (CC) process was investigated by the systematic samplings and analyses for four heats in a steel plant in China. Oxygen/nitrogen analyzer, automatic scanning electron microscope, field-emission scanning electron microscope, and energy spectroscopy analysis were used to analyze the variations of number, size, type, and morphology of inclusions in molten steel from RH to tundish, and X-ray fluorescence was used to analyze the slag composition. The relationship between slag composition and inclusion characteristics in molten steel was investigated. The effect of slag composition on the oxygen mass transfer from the slag–metal interface to liquid steel was also studied through a theoretical calculation. The results showed that the cleanliness of molten steel was greatly affected by the slag composition. The deterioration of steel cleanliness was mainly arisen from a serious reoxidation of molten steel by oxidizing components like (T.Fe + MnO) in top slag during RH refining process. A weak ability to absorb inclusions of top slag with high CaO/Al2O3 and CaO/SiO2 mass ratios was confirmed from the inclusions analyses. The size and number of Al2O3 inclusion clusters were larger, and Ti content in Al2O3-TiO x inclusions was higher from RH to tundish in the case of serious reoxidation. The reduction of FeO content and keeping the CaO/Al2O3 and CaO/SiO2 ratios at about 1.6 and 4–7, respectively, in top slag during RH refining process was beneficial to minimize the reoxidation of Al and Ti and increase the inclusion absorption ability of top slag.

Periclase-magnesium aluminate spinel ceramics filter with excellent purification efficiency on molten steel prepared from Mg(OH)2: Effect of fused MgO content

Reticulated ceramic filters are widely used in the field of steel purification to improve the quality of steel products. In this work, periclase-magnesium aluminate spinel ceramic filters with microporous MgO coating were fabricated by using Mg(OH)2 as raw material. The effect of fused MgO content on the microstructures, mechanical properties and filtration capacity of filters on Al2O3 inclusions in molten steel was comparatively studied. The results indicate that the particle packing and liquid phase sintering cooperated to promote the formation of neck connections between microporous MgO particles, which increased the cold compressive strength and thermal shock resistance of the filters. Furthermore, the results from the immersion test in molten steel demonstrate that an appropriate amount of high-temperature liquid phase and the relatively microporous structure of filter skeleton were favorable for filters to filtrate Al2O3 inclusion in molten steel. Overall, the filter with 30 wt% fused MgO had the best comprehensive performance with a cold compressive strength of 0.68 MPa, a residual retention of cold compressive strength after three thermal shock recycles of 79.07 % and a filtration efficiency of 79.06 % in reducing the total oxygen content of the steel.

Phase equilibria of CaO–Al2O3–CaO·TiO2 system at 1500 °C in hydrogen atmosphere

The phase diagram of CaO–Al2O3-TiOx system is of great importance in guiding the design of metallurgical slag systems for Al–Ti alloy steel, controlling Ti-bearing inclusions in molten steel, and regulating the mineral phase of vanadium-titanium magnetite. In the present work, the high temperature equilibration-quench technique was adopted, and the types and compositions of equilibrium phases were identified by Electron Probe Micro Analysis (EPMA) and X-ray diffraction (XRD). The isothermal section of CaO–Al2O3–CaO·TiO2 system at 1500 °C in H2 atmosphere was constructed for the first time. There are 7 three-phase fields, 10 two-phase fields, and a single liquid phase field. On this basis, according to the theoretical analysis of the crystal structure, the formation energy analysis based on first-principles calculations, and the related theories of defect chemistry, the formation mechanisms of CaTiO3 and Ca3Ti2O7 solid solution with were determined, respectively. Additionally, the experimental phase diagram was utilized to discuss the dissolution type and the equilibrium solubility of typical inclusions (Al2O3, Ti3O5, and CaO·TiO2) in Al–Ti alloy steel.

Large Eddy Simulation of Molten Steel Flow and Inclusion Transport in a New Butterfly-Type Induction Heating Tundish

Large Eddy Simulation of Molten Steel Flow and Inclusion Transport in a New Butterfly-Type Induction Heating Tundish

Investigation of Inclusion Characteristics in Ferrosilicon Killed High Silicon Steels

Industrially, the silicon requirement of liquid steel is often met with ferrosilicon (FeSi) instead of high‐purity silicon addition. FeSi, a silicon‐rich alloy, contains impurities typically inherited from its manufacturing stage. Therefore, FeSi addition results in the formation of complex inclusions in the liquid steel. Herein, a detailed inclusion characterization of the samples obtained from the melting experiments for a wide range of silicon concentrations has been carried out to examine the effect of FeSi impurities. Pure silica inclusions evolve to silica‐ and/or alumina‐based Si–Al–(Ti)–O–(TiN) complex inclusions with the increasing addition of FeSi to the steel melt. Reduction of silica by aluminum or titanium, the presence of titanium in the steel melt, and/or TiN inclusions formed at the periphery of oxide inclusions restrict the growth of oxide inclusions, resulting in small‐sized (average) oxide inclusions. The underlying mechanism of such complex (Si–Al–Ti–O–N)‐based inclusions has been explained with the aid of microstructural characterization and thermodynamic calculations. Moreover, the steel–crucible (alumina) interface has also been investigated for inclusion deposits and crucible–steel interaction.

Effects of Ce addition on inclusion modification in martensitic stainless steel

The control of inclusion features, i.e., chemical composition, distribution, quantity, and size, is in high demand for stainless steels to achieve good surface quality, pitting corrosion resistance, and mechanical properties. In this paper, the effects of rare earth (RE) modification on the inclusions of martensitic stainless steel were explored. Martensitic stainless steels with various contents of Ce were prepared, and the inclusions in the cast billets were characterized by field emission scanning electron microscopy (FE-SEM) and an automatic analysis system for nonmetallic inclusions in steels (OTS). The effect of Ce on the modification of nonmetallic inclusions during solidification was explored with thermodynamic calculations. The results showed that the addition of Ce modified the oxygen and sulfur inclusions by transforming them from irregular elongated inclusions to nearly spherical RE composite inclusions. Compared with those in basic martensitic stainless steel, nine types of RE inclusions were found in the presence of Ce. As the Ce content increased from 0.048 wt% to 0.092 wt%, the CeAlO3 content decreased, whereas the Ce2O2S content increased. Moreover, there were 80% fewer inclusions than in the basic martensitic stainless steel.

Effect of Different Calcium and Magnesium Treatments on the Evolution of Nonmetallic Inclusions in AH36 Ship Plate Steel

Comprehensive thermodynamic calculations and high‐temperature experiments are performed to systematically evaluate the effect of calcium and magnesium additions on the modification and control of inclusions in AH36 ship plate steel. The results show that Al2O3 or MgAl2O4 inclusions are formed under the casting temperature conditions. Calcium treatment modifies the inclusions into calcium aluminate, of which components partially fall into the liquidus region, and the aspect ratio and number density of inclusions became smaller, avoiding nozzle clogging, but the inclusions are easy to gather and grow up, which would affect the steel properties. Magnesium treatment modifies the inclusions into dispersed magnesium‐aluminum spinel with small size. However, the number density and aspect ratio of inclusions increase, as well as the melting points of inclusions are high, which would easily cause nozzle clogging. When calcium–magnesium synergistic treatment, with the increase of magnesium proportion, the inclusions types increased, and the liquidus area of inclusions became narrower until it disappeared. Synergistic treatment with more calcium and less magnesium (Ca2Mg1) is optimal since the inclusions were fine and diffuse, and the corresponding liquidus area of inclusions is wider than the calcium treatment.

Influence of Oxide Inclusions on the Creep Properties of Electron Beam Welds in Ti-added Reduced Activation Ferritic/Martensitic Steel

In this study, the effects of reducing oxide inclusions on the microstructure, tensile properties at 550 ℃, and creep resistance of electron beam welded (EBW) joints in Ti-added reduced activation ferritic/martensitic (RAFM) steel were investigated. Two RAFM steels, designated as Steel A and Steel B, were prepared by adjusting the Al and Si contents to contain different fractions of oxide inclusions. The microstructures of the base metal and heat-affected zone (HAZ) were analyzed, and the mechanical properties of the welds were evaluated. Reducing the Al and Si content in Steel B resulted in a decrease in both the fraction and size of oxide inclusions compared to Steel A. Both steels exhibited tempered martensitic microstructures with M23C6 and MX precipitates. Hardness tests revealed that the over-tempered HAZ (OTHAZ) was the weakest region. However, both tensile test and creep tests at 550 ℃ showed fractures occurring in the base metal, indicating that the low heat input of EBW effectively minimized the weak HAZ regions. Steel B demonstrated improved tensile properties and creep resistance due to the reduced oxide inclusions. It was found that Steel B had a significantly longer creep life than Steel A at 550 ℃. SEM analysis revealed ductile fracture characterized by dimples, where oxide inclusions containing Al, Si, Ta, and Ti were predominant. The presence of these inclusions reduced the effectiveness of solid solution and precipitation strengthening by consuming Ta and Ti. Additionally, microvoids could easily nucleate at the interface between the hard oxide inclusions and the soft metal matrix during creep. Therefore, the reduction of oxide inclusions improved deformation resistance and high-temperature stability, resulting in better creep resistance in Steel B. In conclusion, the reduction of oxide inclusions in Ti-added RAFM steel enhances the high-temperature mechanical properties and creep resistance of EBW joints, underscoring the importance of oxide control in the development of RAFM steels for fusion reactor applications.

Effect of Refractory Crucibles on Inclusions in Ce-Containing High-Aluminum Steel

Effect of Refractory Crucibles on Inclusions in Ce-Containing High-Aluminum Steel